Thermoplastic superabsorbent polymer blend compositions and their preparation

ABSTRACT

An extrudable thermoplastic superabsorbent polymer blend composition is disclosed. The blend compositions are especially well suited for preparation of extruded or molded articles such as monolayer films, multilayer films, nonwoven webs, sheets, foams, profiles, multilayer laminates, fibers, tubes, rods or pipes which in turn are well suited for preparation of power and communication cables or disposable absorbent articles such as diapers, sanitary napkins, tampons, incontinence products, hospital gowns or bed pads.

CROSS REFERENCE STATEMENT

[0001] This application claims the benefit of U.S. ProvisionalApplication No. 60/220,529, filed Jul. 24, 2000.

FIELD OF THE INVENTION

[0002] The present invention relates to a thermoplastic polymer blendcomposition comprising a superabsorbent polymer and method ofpreparation thereof.

BACKGROUND OF THE INVENTION

[0003] Superabsorbent polymers are well-known materials that are used ina variety of applications ranging from personal care articles such asdiapers to water barrier applications in the construction industry towater blocking agents in communications cables to liquid absorbers infood packaging systems. These polymers are known to absorb several timestheir weight of, for example, moisture, water, saline solution, urine,blood, serous body fluids and the like.

[0004] One of the challenges of using superabsorbent polymer particleswithin an absorbent device is the containment or fixation of thesuperabsorbent polymer particles. Depending on the particular absorbentdevice, different approaches to contain or fix the superabsorbentpolymer particles have been taken. For example, disposable absorbentproducts such as diapers, sanitary napkins, tampons, incontinenceproducts, and the like typically comprise a matt or batt wrapped with aliner wherein the batt usually comprises the superabsorbent polymer inparticulate form, see U.S. Pat. No. 3,670,731. However, loss ofparticles and/or redistribution of the particles within the device,sometimes referred to as shakeout, often occurs.

[0005] An attempt to reduce shakeout is taught in U.S. Pat. No.4,806,598 which discloses nonwoven webs made from a thermoplasticpolymer composition comprising a polyoxyethylene superabsorbentcomprising a soft segment bonded to a hard segment through a reactionwith a third segment and a thermoplastic polymer. However, there islittle interaction between the polyoxyethylene superabsorbent and thethermoplastic polymer and the blends are not stable with regard to phaseseparation. Further, webs made from the thermoplastic polymercomposition do not demonstrate adequate wet strength and attempts toimprove the wet strength of the webs by replacing some of thethermoplastic polymer composition with a low density polyethyleneresults in substantially decreasing the water absorbency of the web.

[0006] In power and communication cable applications differentapproaches have been tried to bind or fix superabsorbent polymers aswater-blocking agents. For examples, see U.S. Pat. No. 4,966,809 whichdiscloses water-blocking tapes made by mixing a superabsorbent polymerand a polymeric binder and then spreading the mixture on nonwovenfabrics, see U.S. Pat. No. 5,461,195 which discloses a superabsorbentpolymer mixed with a thixotropic agent to form a gel which is used tofill the spaces between the wires of the cable or see U.S. Pat. No.5,925,461 which discloses strengthening members or buffer tubes coatedor impregnated with a hot melt adhesive comprising a super absorbent.

[0007] Mixtures of superabsorbent polymers and binders are characterizedby a number of disadvantages and/or limitations, such as manufacturingand operating temperature limitations, lack of adhesion to thesubstrates to which the mixture is applied, and delaminating when thearticle is pulled in the tensile direction, that contribute to abrasionwhen the article is being fabricated and the like. Further, tapes addadditional components in the construction of cables causing considerableunwanted increases in their costs and diameters. Cables using fillergels are characterized by a number of disadvantages and/or limitationssuch as manufacturing and operating temperature limitations, formationof voids which lead to paths of water migration, and difficultiesmeeting industry standards.

[0008] Other methods to bind superabsorbent polymers are known. Forexample see, U.S. Pat. No. 5,516,585 which discloses a method of coatingdiscontinuous fibers with a thermoset binder material which bindsparticles of superabsorbent wherein the discontinuous fibers are formedinto a web. In a method described in U.S. Pat. No. 4,392,908superabsorbent polymer particles are coated with a thermoplastic resinand fixed to a water-absorbent substrate by applying heat to soften thethermoplastic coating of the particles and pressing the particles andsubstrate to cause the particles to bind to the substrate. These methodsare expensive requiring specialized equipment and/or many steps and havelimited commercial applicability.

[0009] Further, films and laminates of superabsorbent polymers have beenmade from solutions of superabsorbent polymers followed by heatingand/or removing the solvent. For examples of cross-linked superabsorbentpolymer films and laminates see U.S. Pat. Nos. 3,926,891, 4,076,673 and4,117,184. For examples of non-cross-linked superabsorbent polymer filmssee U.S. Pat. Nos. 3,935,099, 3,997,484 and 4,090,013. U.S. Pat. No.3,669,103 describes a method to make thin foamed polyurethane thermosetsheet comprising superabsorbent polymer particles. Unfortunately, thesemethods of forming films, laminates and sheet are impractical forlarge-scale commercial use.

[0010] It would be desirable to have a superabsorbent polymercomposition with improved containment of superabsorbent polymerparticles for use in absorbent devices such as personal-care articlesand cable wrap components while maintaining good absorptive properties.Further, it would be desirable for such a superabsorbent polymercomposition to be easily and conveniently shaped into a variety ofuseful forms, especially on a commercial scale.

SUMMARY OF THE INVENTION

[0011] The present invention is such a composition. It is athermoplastic superabsorbent polymer blend composition comprising (a) asuperabsorbent polymer (b) a thermoplastic resin and optionally (c) asurfactant wherein components (a) and (b) interact with each otherionically or covalently and the blend composition can be formed byextrusion, for example, into film, sheet, laminates, foams, profiles andinjection molded articles.

[0012] In another aspect, the present invention is a process forpreparing the abovementioned extrudable thermoplastic superabsorbentpolymer blend composition.

[0013] In a further aspect, the present invention involves a method ofextruding or molding the abovementioned extrudable thermoplasticsuperabsorbent polymer blend composition.

[0014] In yet a further aspect, the invention involves extruded (e.g.,film, sheet, foam, laminates, and the like) or molded articles of theabovementioned extrudable thermoplastic superabsorbent polymer blendcomposition.

[0015] In yet a further aspect, the invention involves articlescomprising extruded or molded articles of the abovementioned extrudablethermoplastic superabsorbent polymer blend composition.

[0016] The blend compositions and extruded and molded articles of thepresent invention may be employed in a wide variety of uses as are knownin the art, such as, for example, the assembly or construction of cablewrap components and various disposable absorbent articles, such assanitary napkins, disposable diapers, hospital gowns, bed pads and thelike.

DETAILED DESCRIPTION OF THE INVENTION

[0017] The superabsorbent water-swellable or lightly cross-linkedhydrophilic polymers suitably employable in the present invention can beany of the known hydrophilic polymers that are capable of absorbinglarge quantities of fluids. These polymers are well known in the art andare widely commercially available.

[0018] Examples of some suitable polymers and processes, including gelpolymerization processes, for preparing superabsorbent polymers aredisclosed in U.S. Pat. Nos. 3,997,484; 3,926,891; 3,935,099; 4,090,013;4,093,776; 4,340,706; 4,446,261; 4,683,274; 4,459,396; 4,708,997;4,076,663; 4,190,562; 4,286,082; 4,857,610; 4,985,518; and 5,145,906,which are incorporated herein by reference. In addition, see Buchholz,F. L. and Graham, A. T., “Modern Superabsorbent Polymer Technology,”John Wiley & Sons (1998) and Lisa Brannon-Peppas and Ronald S. Harland,“Absorbent Polymer Technology” Elsevier (1990).

[0019] Preferred superabsorbent polymers are prepared from water-solubleα,β-ethylenically unsaturated monomers such as monocarboxylic acids,vinyl polycarboxylic acids, acrylamide and their derivatives. Morepreferred superabsorbent polymers are cellulosic or starch-graftcopolymers, such as starch-g-poly(acrylonitrile), starch-g-poly(acrylicacid) and the like; polyacrylamides; polyvinyl alcohols; poly(acrylicacids); high molecular weight polymers, preferably cross-linked, ofethyleneoxide (EO) and propyleneoxide (PO); copolymers of sulfonic acidgroup containing monomers, such as vinyl sulfonic acid, sodiumsulfoethyl methacrylate, 2-Acrylamido-2-Methylpropane-sulfonic acid orthe sodium salt (AMPS) and the like.

[0020] Most preferred superabsorbent polymers are crosslinked, partiallyneutralized and/or surface treated. Preferably, the level ofcrosslinking is selected to give the desired swelling characteristicsfor the particular application. Generally, the degree of neutralizationis from about 30 to about 100 percent, more preferably from about 50 toabout 80 percent. Neutralization with a basic substance containing aGroup I metal ion, such as sodium, is preferred. A preferred surfacetreatment consists of a post polymerization reaction to effect thesurface crosslinking of the superabsorbent polymer.

[0021] The amount of the superabsorbent polymer to be included in thethermoplastic superabsorbent polymer blend composition according to thepresent invention will vary depending, for example, upon the type ofsuperabsorbent polymer used, the type of thermoplastic resin used, thedesired extruded or molded product, the extruded or molded product's enduse application, the desired level of blocking, absorbing or stoppingthe migration of water and/or other fluids in the end use application,etc.

[0022] The superabsorbent polymer is present in an amount equal to orgreater than about 1 part per weight, preferably equal to or greaterthan about 5 parts per weight, more preferably equal to or greater thanabout 10 parts per weight, even more preferably equal to or greater thanabout 15 parts per weight and most preferably equal to or greater thanabout 20 parts per weight based on the weight of the thermoplasticsuperabsorbent polymer blend composition. The amount of superabsorbentpolymer is present in an amount equal to or less than about 70 part perweight, preferably equal to or less than about 65 parts per weight, morepreferably equal to or less than about 60 parts per weight, even morepreferably equal to or less than about 55 parts per weight and mostpreferably equal to or less than about 50 parts per weight based on theweight of the thermoplastic superabsorbent polymer blend composition.

[0023] In addition to a superabsorbent polymer, the blend composition ofthe present invention contains at least one thermoplastic resin thatinteracts (i.e., ionically, covalently, etc.) with the superabsorbentpolymer. For example, a thermoplastic resin having an acyl groups whichcan undergo nucleophilic attack resulting in a substitution reaction inwhich a leaving group, such as —OH, —Cl, —OOCR, —NH2 or —OR, is replacedby another basic group present in the superabsorbent polymer. Anotherexample is a thermoplastic resin containing carbonyl groups that canundergo a nucleophilic attack gaining a proton and adding another basicgroup present in the superabsorbent polymer. Under these conditions thereaction product of the thermoplastic resin and superabsorbent polymermay form a uniform and/or co-continuous non-separating polymer blend.

[0024] Preferred thermoplastic resins have functional groups such asacyl or carbonyl groups (e.g., α,β-unsaturated carbonyl compounds,hydroxy acids, dicarboxylic acids, keto acids, anhydrides, carboxylicacids, aldehydes, ketones, acid halides, esters, amides, etc.),sulfonyls, sulfonyls halides, ethers, phenols, aryl halides, epoxides,carbohydrates, alcohols, azides, amines and the like.

[0025] The preferred thermoplastic resins are acrylic polymers, withpolyacrylic acid (PAA), ethylene and acrylic acid copolymers (EAA),ethylene, t-butylacrylate and acrylic acid terpolymer (EtBAAA), ethyleneand methacrylic acid copolymers (EMAA), ionomers of ethylene andmethacrylic acid copolymers especially the sodium and zinc ionomers,ethylene, vinyl acetate and carbon monoxide terpolymers (EVACO),ethylene and carbon monoxide copolymers (ECO), ethylene, acrylic acidand carbon monoxide terpolymers (EAACO), ethylene, n-butylacrylate andcarbon monoxide terpolymers (EnBACO) and blends thereof being mostpreferred.

[0026] The most preferred thermoplastic resins are 1) an EAA copolymer,wherein the EAA copolymer may be a blend of two or more EAA copolymers,preferably having a composition from about 10 to about 20 weight percentacrylic acid based on the weight of the copolymer and a melt flow rate(MFR) from about 100 to about 200 grams per 10 minutes (g/10 min.) underconditions of 190° C. and an applied load of 2.16 kg., 2) ionomers ofEMAA, preferably the zinc ionomer, 3) EVACO, preferably having a carbonmonoxide content of at least 9 percent based on the weight of theterpolymer or 4) blends thereof.

[0027] The thermoplastic resin is present in an amount equal to orgreater than about 30 part per weight, preferably equal to or greaterthan about 35 parts per weight, more preferably equal to or greater thanabout 40 parts per weight, even more preferably equal to or greater thanabout 45 parts per weight and most preferably equal to or greater thanabout 50 parts per weight based on the weight of the thermoplasticsuperabsorbent polymer blend composition. The amount of thermoplasticresin is present in an amount equal to or less than about 99 parts perweight, preferably equal to or less than about 95 parts per weight, morepreferably equal to or less than about 90 parts per weight, even morepreferably equal to or less than about 85 parts per weight and mostpreferably equal to or less than about 80 parts per weight based on theweight of the thermoplastic superabsorbent polymer blend composition.

[0028] It should be apparent to those having ordinary skill in the artthat the present invention contemplates blends containing two or moresuperabsorbent polymers and/or blends of two or more thermoplasticresins (e.g., EAA/EVACO, EMAA/EAA, a first EAA/a second EAA and thelike).

[0029] While the blend compositions of the present invention contain atleast one superabsorbent polymer, such blend compositions may or may notbe superabsorbent, depending upon the level and absorbency of thesuperabsorbent polymer in the blend composition and the availability ofthe superabsorbent polymer to aqueous media.

[0030] The blend compositions of the present invention can be furtherblended with other thermoplastic polymers, preferably low densitypolyethylene (LDPE), linear low density polyethylene (LLDPE), very lowdensity polyethylene (VLDPE), polypropylene (PP), polystyrene (PS),ethylene and methylacrylate copolymer (EMA), ethylene and ethylacrylatecopolymer (EEA), ethylene and n-butylacrylate copolymer (EnBA),polyethylene grafted with maleic anhydride grafted (PE g-MAH), ethyleneand vinyl acetate copolymer (EVA), ethylene and vinyl acetate copolymergrafted with maleic anhydride grafted (EVA g-MAH), or combinationsthereof.

[0031] The blend compositions of the present invention may furthercomprise additional additives commonly used in compositions of this typesuch as lubricants, extenders, compatibilizers, plasticizers, low andhigh molecular weight waxes, surfactants, stabilizers, pigments, carbonblack and fillers such as talc, titanium dioxide (TiO₂), calciumcarbonate (CaCO₃), magnesium oxide (MgO), mica and the like.

[0032] The blend compositions of the present invention may further beblended with a solvent to form a dispersion or paste. One skilled in theart can readily choose the type and amount of solvent depending on theparticular end use.

[0033] As used herein, the phrase “extrudable thermoplasticsuperabsorbent polymer blend composition” means that: (1) the blendcomposition is melt processable in an extrusion, injection moldingand/or blow molding process, (2) the extrudate is either commuted topellets or directly extruded or molded by extrusion fabricationtechnique, (3) the pellets have a measurable melt flow rate, melt drawrate and melt strength sometimes referred to as melt tension and (4) thepellets can be re-extruded by an extrusion fabrication techniques.Preferably, the blend compositions of the present invention do not causeplugging, die-face build up, surging, melt fracture, pinholes, tearingand/or poor extrudate properties (i.e., strand dropping, delamination,etc.) during the extrusion process.

[0034] A melt indexer is used to determine melt flow rate (MFR), melttension and draw down rate. MFR is determined by ASTM D 1238; the runconditions (i.e., temperature and applied load) depend upon thethermoplastic resin used. Melt tension is determined from a load cellattached at the bottom of the melt indexer which measures the loadrequired to pull the extrudate from the die of the melt indexer to atake up reel at some given speed measured in feet per minute (fpm). Thedraw down rate (fpm) is determined by how fast the extrudate coming outof the melt indexer can be pulled before it breaks. When MFR conditionsare selected to give a MFR between about 0.1 and about 300 g/10 min. thethermoplastic superabsorbent polymer blend composition has a melt drawdown rate between about 5 and about 100 fpm and a melt tension betweenabout 0.1 and about 10.

[0035] The components of the extruded blend composition can beco-continuous or separate phases (one being continuous and one or morebeing dispersed therein) as long as phase separation does not have asignificant deleterious effect on the melt processability or performanceof the blend composition.

[0036] Preferred extrusion fabrication techniques include preparing meltblown or cast films; extrusion coating; (co)extruding nonwoven webs,including spun bond nonwoven webs, melt blown nonwoven webs, orcomposites comprising combinations thereof, sheets, foams, profiles,multilayer laminates, fibers including monofilament fibers andbicomponent monofilament fibers, tubes, rods or pipes; blow moldingarticles; injection molding articles (including solid, co-injection,structural foam and gas assist injection molding). Preferred nonwovenwebs comprise spun bond nonwoven webs comprising one or more bicomponentfiber, melt blown nonwoven webs comprising one or more bicomponentfiber, and a composite structure comprising at least one layer of one ormore spun bond nonwoven web and at least one layer of one or more meltblown nonwoven web wherein one or more layers of the composite comprisebicomponent fibers.

[0037] The thermoplastic superabsorbent polymer blend compositions ofthe present invention can be extruded into foam using a chemical orphysical blowing agent. Further, the thermoplastic superabsorbentpolymer can be blended with other miscible or compatible thermoplasticpolymers such as LDPE, LLDPE, VLDPE, PP, PS, EEA, EMA, ENBA, PE g-MAH,EVA, EVA g-MAH or the like. One skilled in the art can choose the typeand amount of blowing agent as well as other polymers to blend with thethermoplastic superabsorbent polymer for the particular end use in orderto modify the cell size, structure, porosity, microcellular nature andabsorbency characteristics of the thermoplastic superabsorbent polymerfoam as desired.

[0038] The blend compositions to make foam may further compriseadditional additives commonly used in compositions of this type such aslubricants, extenders, nucleators, compatibilizers, plasticizers, lowand high molecular weight waxes, surfactants, stabilizers, pigments,carbon black and fillers such as talc, TiO₂, CaCO₃, MgO, mica and thelike.

[0039] Further, extruded pellets or sheet can be compression molded;calendered; vacuum formed or thermoformed. Preparation of thethermoplastic superabsorbent polymer blend compositions of thisinvention can be accomplished by any suitable mixing means known in theart. Typically the components and any additional additives are blendedin a tumbler or shaker in powder, particulate and/or pellet form withsufficient agitation to obtain thorough distribution thereof. Thedry-blended formulation can further be subjected to shearing stresses ata temperature sufficient to heat soften and melt-mix the polymers, forexample in an extruder, with or without a vacuum, or other mixingapparatuses (e.g., a Banbury mixer, roller mill, Henschel mixer, aribbon blender, etc.). Further, additional powder, particulate and/orliquid additives may be added to the composition during the mixingprocess. Such melt-mixed material can be extruded to make the finishedarticle (i.e., film, sheet, foam, profile, etc.) or recovered in theform of a pellet, powder or flake, preferably a pellet. The extrudatemay be commuted to pellets by any conventional means such as a strandchopper or an underwater die face cutter.

[0040] The extrudate from the melt-mixing may be cooled by any methodknown in the art, such as air cooled, gas cooled, belt cooled, liquidcooled by passing through a liquid bath, and the like. Preferably astainless steel belt cooler, for example manufactured by Sandvik ProcessSystems, Sweden or a Compact Conti Cooler manufactured by BBA AG,Switzerland, or an aqueous liquid bath, preferably where the pH is lessthan 1.0 or an aqueous liquid bath with a water hardness of greater than25 French Degrees, more preferably an aqueous liquid bath with aspecific gravity greater than about 1.05 as measured with a desitometeris used. The aqueous bath preferably contains a saturated salt solutioncontaining a Group 1 metal ion, preferably sodium, such as sodiumchloride (NaCl), sodium sulfate (Na₂SO₄), sodium bicarbonate (NaHCO₃)and the like.

[0041] Further, to minimize the effect of the water on thesuperabsorbent compound it has been discovered that maintaining thetemperature of the liquid bath less than about 23° C. and preferablyless than about 20° C. effectively cools the pellets without grosslyactivating the superabsorbent polymer in the blend composition.

[0042] It has farther been found that when using an underwaterpelletizer, optimizing the transfer pipe length from the underwaterpelletizer to the separating dryer minimizes the activation of thesuperabsorbent polymer in the blend composition.

[0043] Blowing cool air in the pellet-collecting vessel, such as the useof a fluidized bed cooler, to drive away the remaining moisture on thepellets further improves the drying process.

[0044] It has been found using a process comprising an underwater dieface cutter, a saturated NaHCO₃ solution having a specific gravitygreater than about 1.05 and a temperature less than 20° C. and blowingcool air in the pellet-collecting vessel yields an extrudablethermoplastic superabsorbent polymer blend composition in a free flowingplastic pellet form having a moisture content ranging from 0.2 to 4weight percent depending on the superabsorbent polymer, concentration ofsuperabsorbent polymer in the blend composition and the basethermoplastic resin, wherein moisture weight percent is based on theweight of the blend composition.

[0045] The melt-mixed material (powder, flake or pellet) can bere-extruded or molded to make the finished article. Dry blends of theblend compositions can also be directly injection molded or metered intoanother melt fabrication process without pre-melt-mixing.

[0046] The extrudable thermoplastic superabsorbent polymer blendcompositions of the present invention are useful in the pellet, flake orpowder form for use in cat litter, solidified gases/fluids, gelled ice,soil conditioner, frost control, agricultural delivery systems, gelledbiohazards, spill control, for the fabrication of articles such asfoams, such as closed, semi-porous or microcellular or open cell,bicomponent fibers and waterproof or waterblocking coating systems,thick film or sheet for such applications as disposable absorbentarticles, such as sanitary napkins, disposable diapers, hospital gowns,bed pads and the like, films for such applications as moisture sensitivesystems, moisture, such as water, absorbing structures, for example inpackaging, transportation, construction applications and the like,diaper backing, meat trays, carpet backing or power and communicationcable water-blocking tapes, film for laminate structures such aslaminated foam structures, laminated non-woven structures, film forlaminates for such applications as cable shielding tapes for use inpower cables or communication cables, such as fiber optical cables,copper pair cables, coaxial cables and the like as disclosed in U.S.Pat. Nos. 3,795,540, 4,449,014, 4,731,504 and 4,322,574, which areincorporated herein by reference.

[0047] It is further desirable that when the present invention is usedin the construction of cables for example, power cables andcommunication cables, such as fiber optical cables, copper pair cables,coaxial cables and the like, the cables meet certain requirements ofwater penetration. Most desirably, a cable structure comprising anextrudable thermoplastic superabsorbent polymer blend compositionresists penetration, sometimes referred to as water blocking, of waterthrough the cable in the longitudinal direction.

[0048] To illustrate the practice of this invention, examples are setforth below.

EXAMPLES Thermoplastic Superabsorbent Polymer Blend Compositions

[0049] In Comparative Examples A to ZZ and Examples 1 to 13 differentthermoplastic resins are melt blended in a Brabender Plasticoder withCABLOC™ 850-13 a sodium polyacrylate superabsorbent polymer that issurface cross-linked having a particle size distribution of about 1 toabout 300 micrometers available as a powder from Stockhausen andsupplied by the Stewart Superabsorbents LLC. Unless otherwise noted, theratio of superabsorbent polymer to thermoplastic resin is 40:60. TheBrabender Plasticoder conditions are: Barrel temperature ranging from275 to 420° F. depending on the thermoplastic resin being used; Mixingrevolutions per minute (RPM) are 80; and Mixing times range from 1.5 to2 minutes. A melt indexer is used to determine the melt flow rate, melttension and melt draw down rate of the polymer blends

[0050] Table 1 lists the compositions for Comparative Examples A to ZZand Examples 1 to 13 and their properties. In Table 1 blend compositionswhich can be melt blended in some fashion and pressed into a shape ormolded into a sheet or an article, but do not meet the criteria setforth herein as extrudable are designated not extrudable.

[0051] Comparative Examples AB to AN and Examples 14 to 17 arecompounded on a WP ZK30 twin screw extruder. The SAP and the polymer arefed separately into the feed section of the extruder, the vent port ofthe extruder is open to the atmosphere and the extrudate is air-cooled.

[0052] The compositions of Comparative Examples AB to AN and Examples 14to 17 and extruder temperatures are given in Table 2, the superabsorbentpolymer is present in parts by weight based on the weight of thethermoplastic superabsorbent polymer blend composition. In Table 2compositions that demonstrate die face build-up and/or plugging aredesignated “not” extrudable. TABLE 1 Thermoplastic SuperabsorbentPolymer Blend Composition MFR, Melt Draw Exam- Com. Thermoplastic ResinMFR, g/10 Tension, Rate, Extrud- ple Ex. Grade Supplier Type Conditionmin units fpm able A ALATHON ™ M6060 Equistar HDPE E 5.20 No B LDPE 4005Dow Chemical Co. LDPE E 1.98 No C LDPE 4012 Dow Chemical Co. LDPE E 4.50.8 <5 No D LDPE 681 Dow Chemical Co. LDPE E 0.72 No E DOWLEX ™ 2247ADow Chemical Co. LLDPE E 1.33 No F ASPUN ™ 6821 Dow Chemical Co. LLDPE B11.2 No G ATTANE ™ 4201 Dow Chemical Co. VLDPE E 0.417 No H ATTANE 4402Dow Chemical Co. VLDPE E 1.16 No I AFINITY ™ 1880 Dow Chemical Co.INSITE ™ PE E 0.594 No J ENGAGE ™ 8200 DuPont Dow INSITE PE E 3.26 No KPP 861 Montell PP L 7.6 No L PS 680 Dow Chemical Co. PS G 5.8 No MChevron 2252-T Chevron EMA E 0.42 No N Chevron 2255 Chevron EMA E 1.30No O Chevron 1802 Chevron EnBA E 0.44 No P ENGAGE SM8400 Dow ChemicalCo. PE g-MAH/high MAH E 0.28 No Q FUSABOND ™ 190D DuPont EVA g-MAH/highMAH E 0.5 No R FUSABOND 197D DuPont EVA g-MAH/high MAH E 0.1 No SFUSABOND 226D DuPont LLDPE g-MAH/high MAH E 0.1 No T FUSABOND 274DDuPont EPDM g-MAH/medium MAH E 0.1 No U FUSABOND 413D DuPont PE g-MAHMAH E No V FUSABOND 423G DuPont EA terpolymer g-MAH/high MAH E 1.43 No WFUSABOND 353D DuPont PP g-MAH/very high MAH 160° C./ 2.62 No 0.353 Kg XBYNEL ™ E418 DuPont Anhydride Modified EVA E 2.41 No Y CXA 3101 DuPontAcid/Acrylate Modified EVA E 1.71 No Z CXA 4105 DuPont AnhydrideModified LLDPE E 0.84 No AA BYNEL 50E561 DuPont Anhydride Modified PP E0.90 No BB BYNEL 2174 DuPont Anhydride Modified EA E 0.75 No CC PLEXAR ™3 Equistar Anhydride Modified EVA E 1.24 No DD PLEXAR 206 EquistarAnhydride Modified HDPE E 2.77 No EE STEREON ™ 841A Firestone SBS blockcopolymer G 5.42 No FF VECTOR ™ 4211 Dexco Polymers SIS block copolymerG 11.58 No GG VECTOR 4461 Dexco Polymers SBS block copolymer G 9.72 NoHH KRATON ™ G1657 Shell SEBS block copolymer G 3.82 No II KRATON FG1901XShell SEBS block copolymer G 0.25 No JJ VECTOR 4411 Dexco Polymers SISblock copolymer G 18.2 No KK Phillips DK-11 Phillips SBS block copolymerG 3.62 No LL Phillips K-10 Phillips SBS block copolymer G 4.6 No MMVECTOR 8508 Dexco Polymers SBS block copolymer G 3.1 No NN ESI DE 200Dow Chemical Co. Ethylene-Styrene Interpolymer G 4.75 No OO ESI DS 201Dow Chemical Co. Ethylene-Styrene Interpolymer G 5.6 No PP ELVAX ™ 3180DuPont EVA, 28% VA E 13.68 No QQ ELVAX VOW DuPont EVA, 49% VA B 1.5 NoRR GRILTEX ™ 9 EMS Am. Grilon, Inc CoPolyester hot melt adhesive C 4.4No SS GRILTEX D EMS Am. Grilon, Inc CoPolyester hot melt adhesive C 2.3No 1519EGF TT MACROMELT ™ Henkel Polyamide Resin C No 6238 UU MACROMELT6206 Henkel Polyamide Resin C 24.52 No VV PHAE Dow Chemical Co.Thermoplastic Phenoxy Resin E 7.5 No WW LDPE 457 Dow Chemical Co. ECO,1% CO E 0.33 No 1 ELVALOY ™ HP441 DuPont EnBACO E 3.1 1.5 5 Yes 2ELVALOY EP4924 DuPont EVACO E 7.28 0.5 20 Yes 3 A702 Chevron EEA E 2.81.0 5 Yes XX PRIMACOR ™ 3330 Dow Chemical Co. EAA, 6.5% AA E 2.2 No 4PRIMACOR 1410 Dow Chemical Co. EAA, 9.7% AA E 0.72 Yes 5 PRIMACOR 1430Dow Chemical Co. EAA,; 9.7% AA E 2.43 1.0 5 Yes 6 PRIMACOR 3460 DowChemical Co. EAA, 9.7% AA E 8.98 0.6 20 Yes 7 XUS70751.17 Dow ChemicalCo. EAA, 20.5% AA B 0.84 1.5 10 Yes YY PRIMACOR 5980 Dow Chemical Co.EAA, 20.5% AA B 0.3 No 8 PRIMACOR blend (a) Dow Chemical Co. EAA, 15.1%AA B 1.16 1.4 10 Yes 9 ESCOR ™ ATX 325 Exxon EMAAA E 8.72 0.2 5 Yes 10 NUCREL ™ 699 DuPont EMAA B 4.6 0.5 5 Yes 11  SURLYN ™ 8660 DuPontNa-EMAA Ionomer 125° C./ 1.46 2.0 5 Yes 5.0 Kg 12  SURLYN 1702 DuPontZn-EMAA Ionomer E 6.0 0.9 45 Yes 13  SURLYN 1702 (b) DuPont Zn-EMAAIonomer E 4.13 0.5 20 Yes ZZ SURLYN 1702 (c) DuPont Zn-EMAA Ionomer E2.58 No

[0053] TABLE 2 Blend Compo- Extruder Exam- Com. Thermoplastic ResinSuperabsorbent sition, parts Temperatures ple Ex. Grade Supplier TypePolymer Resin SAP ° F. Extrudable AB LDPE 681 Dow Chemical Co. LDPESAP-1 80 20 310-330 No AC LDPE 681 Dow Chemical Co. LDPE SAP-1 75 25310-330 No AD LDPE 681 Dow Chemical Co. LDPE SAP-1 65 35 310-330 No AELDPE 681 Dow Chemical Co. LDPE SAP-1 60 40 310-330 No AF ATTANE 4201 DowChemical Co. VLDPE SAP-2 80 20 335-370 No AG ATTANE 4203 Dow ChemicalCo. VLDPE SAP-1 73 27 321-350 No AH ALATHON 6030 HPPE Equistar HDPESAP-2 80 20 335-370 No AI DOWLEX 2045 Dow Chemical Co. LLDPE SAP-2 75 25400-420 No AJ ELVAX 3180 DuPont EVA, 28% VA SAP-1 60 40 250-260 No AKAqua Calk (a) Sumitomo Seika Polyethylene Oxide(a) SAP-1 60 40 250-260No Chemical Co., Ltd. AL PRIMACOR 3330 Dow Chemical Co. EAA, 6.5% AASAP-1 60 40 310-330 No 14 PRIMACOR 3460 Dow Chemical Co. EAA, 9.7% AASAP-1 60 40 250-260 Yes AM PRIMACOR 5980 Dow Chemical Co. EAA, 20.5% AASAP-1 60 40 250-260 No 15 PRIMACOR blend (b) Dow Chemical Co. EAA, 15%AA SAP-2 60 40 250-260 Yes AN PRIMACOR blend (b) Dow Chemical Co. EAA,15% AA SAP-2 50 50 250-260 No 16 PRIMACOR 3460 Dow Chemical Co. EAA,6.5% AA SAP-3 60 40 250-260 Yes 17 ELVALOY EP4924 DuPont EVACO SAP-4 6040 250-260 Yes

[0054] Comparative Examples AO to AW are different neat thermoplasticresins, Comparative Example AU is neat superabsorbent polymer CABLOC850-13, AV is the neat superabsorbent polymer CABLOC 80HS, AW is theneat superabsorbent polymer CABLOC 88HS and Examples 18 to 30 aredifferent thermoplastic resins compounded with a superabsorbent polymer.A ZSK 58 millimeter (mm) co-rotating bi-lobe twin screw extruder havinga low shear mixing screw and 10 temperature zones is used. Thesuperabsorbent polymer is fed using a side port powder screw feederbetween zones 4 and 5. Mixing occurs in zone 6. The transition pointbetween zone 8 and 9 is the vent port. There is a kneading mixingsection prior to the vent port. The temperature range for the first 3zones is from 65 to 120° F., for zones 4 and 5 it is from 240 to 255°F., for zones 6 to 8 it is from 320 to 335° F. and for zones 9 and 10 itis from 270 to 330° F. The melt temperature is maintained at 310° F.

[0055] The blend compositions are extruded through a 24 hole underwaterdie having hole diameters of 0.110 inch into a liquid bath containing aNaHCO₃ solution having a specific gravity of greater than 1.05 asmeasured with a desitometer with a temperature maintained below 20° C. AGala underwater pelletizer with 3 cutting blades is used to pelletizethe extrudate. The distance from the underwater pelletizer to theseparating dryer is optimized to minimize the adsorption of water.Further, cool air is blown on the pellets in the pellet-collectingvessel driving away any remaining moisture on the pellets.

[0056] The absorption capacity in pure water (WAC) of the neatthermoplastic resins Comparative Examples AO to AT, the neatsuperabsorbent polymers Comparative Examples AU to AW and thethermoplastic superabsorbent polymer blend compositions Examples 18 to30 is measured according to the following procedure: For thethermoplastic superabsorbent polymer blend compositions a sampledetermined to contain 1 gram of the superabsorbent polymer (based on thepercent superabsorbent polymer in the blend composition) weighing W₁ isplaced in 1.5 liter of distilled water and is shaken on a shaker for 2hours. The water is filtered from the swollen particles through a 75micrometer sieve. The weight of the swollen particles (W₂) is thenmeasured. The amount of water absorbed, W_(a), is W₂-W₁. For the neatresins and neat superabsorbent polymers a sample weighing 1 gram issubjected to the same procedure described herein above.

[0057] The compositions and water absorbed for Comparative Examples AOto AW and Examples 18 to 30 are shown in Table 3, the superabsorbentpolymer is present in parts by weight based on the weight of thethermoplastic superabsorbent polymer blend composition and waterabsorption is reported as grams of distilled water absorbed per gram ofsuperabsorbent polymer. TABLE 3 CABLOC CABLOC CABLOC Example Com. Ex.Thermoplastic Resin 850-13, parts 8OHS, parts 88HS, parts WaterAbsorption, g AO SURLYN 1702 0 18 SURLYN 1702 35 3 19 SURLYN 1702 45212  20 PRIMACOR blend (a) 40 214  21 ELVALOY EP4924 40 231  22 PRIMACOR3460 40 239  23 SURLYN 1702 20 2 24 PRIMACOR blend (a) 20 1 25 PRIMACORblend (a) 30 2 AP PRIMACOR blend (a) 0 26 PRIMACOR blend (b) 40 126  AQELVALOY EP4924 0 27 ELVALOY EP4924 20 2 28 PRIMACOR 3460 40 118  ARXUS60751.17 0 29 SURLYN 1702 35 1 AS PRIMACOR 1430 0 30 SURLYN 1702 4596  AT PRIMACOR 5980 0 AU 100 172  AV 100 198  AW 100  153 

Thermoplastic Superabsorbent Polymer Blended with Polyethylene

[0058] In Examples 31 to 38 thermoplastic superabsorbent polymer is meltblended in a Brabender Plasticoder with a 70:30 LLDPE:LDPE polymerblend. The thermoplastic superabsorbent polymer comprises 40 weightpercent CABLOC T5066-F which is a sodium polyacrylate superabsorbentpolymer that is surface cross-linked having a particle size distributionof about 1 to about 60 micrometers available as a powder fromStockhausen and supplied by the Stewart Superabsorbents LLC and 60weight percent of a 50:50 PRIMACOR 5980:PRIMACOR 3460 polymer blend. TheBrabender Plasticoder conditions are: Barrel temperature is set at 275°F.; Mixing RPM is 80; and Mixing times range from 1.5 to 2 minutes. Amelt indexer is used to determine the melt flow rate, melt tension andmelt draw down rate of the polymer blends. The blend compositions areconsidered extrudable. The compositions of Examples 31 to 38 and theirMFR, melt tension and draw rates are given in Table 4. TABLE 4LLDPE:LDPE Blend Thermoplastic Resin: polymer blend Ratio MFR, MFR, MeltTension, Draw Rate, Example Superabsorbent Polymer “A” “B” A:B Conditiong/10 min units fpm Extrudable 31 60:40 70:30 90:10 C 3.51 0.7  50 YesPRIMACOR BLEND:CABLOC T5066F LLDPE:LDPE 32 60:40 70:30 80:20 C 4.43 0.8 48 Yes PRIMACOR BLEND:CABLOC T5066F LLDPE:LDPE 33 60:40 70:30 60:40 C6.01 0.9  48 Yes PRIMACOR BLEND:CABLOC T5066F LLDPE:LDPE 34 60:40 70:3020:80 C 6.17 1.0  34 Yes PRIMACOR BLEND:CABLOC T5066F LLDPE:LDPE 3560:40 70:30 90:10 E 24.7 0.5 100 Yes PRIMACOR BLEND:CABLOC T5066FLLDPE:LDPE 36 60:40 70:30 80:20 E 25.7 0.6 100 Yes PRIMACOR BLEND:CABLOCT5066F LLDPE:LDPE 37 60:40 70:30 60:40 E 28.1 0.7 100 Yes PRIMACORBLEND:CABLOC T5066F LLDPE:LDPE 38 60:40 70:30 20:80 E 21.9 0.8 100 YesPRIMACOR BLEND:CABLOC T5066F LLDPE:LDPE

Monolayer Films

[0059] Examples 39 to 42 are monolayer films of thermoplasticsuperabsorbent polymer blend compositions produced using a cast lineprocess. The thermoplastic superabsorbent polymer blend compositionscomprise a thermoplastic resin and CABLOC 850-13. The temperature zonesfor the cast film process range from 250° F. to 320° F. The feedblockand die temperatures range from 270° F. to 320° F. Smooth to textureduniformed film having a thickness greater than 6.0 mils or web filmhaving a thickness less than 6.0 mils can be made depending on the takeup speed.

[0060] The compositions and properties of monolayer films Examples 39 to42 are shown in Table 5, the superabsorbent polymer is present in partsby weight based on the weight of the thermoplastic superabsorbentpolymer blend composition. Absorption capacity in pure water wasdetermined by as described hereinabove. TABLE 5 CABLOC ExampleThermoplastic Resin 850-13, parts Water Absorption, g 39 SURLYN 1702 3525 40 SURLYN 1702 45 226 41 PRIMACOR blend (a) 40 219 42 ELVALOY EP492440 238

Monolayer Films Containing Surfactant

[0061] Examples 43 to 46 are mono layer films containing a surfactant.The thermoplastic superabsorbent polymer is melt blended in a BrabenderPlasticoder with a commercially available polyethylene containingsurfactant compound. The polyethylene containing surfactant is availablefrom AMPACET as ANTIFOG PE MB and contains 10 weight percent activesurfactant, mono- and di- glycerides, in a LLDPE/LDPE base polymer. Thethermoplastic superabsorbent polymer comprises 40 weight percent CABLOCT5066-F a sodium polyacrylate superabsorbent polymer that is surfacecross-linked having a particle size distribution of about 1 to about 60micrometers available as a powder from Stockhausen and supplied by theStewart Superabsorbents LLC and 60 weight percent of a 50:50 PRIMACOR5980:PRIMACOR 3460 polymer blend. The Brabender Plasticoder conditionsare: Barrel temperature is set at 275° F.; Mixing RPM is 80; and Mixingtimes range from 1.5 to 2 minutes. Water absorption and rate ofabsorption is measured by placing a 2 inch disc sample of a 5 to 7 milcompression molded film in a 2 inch diameter cylinder. At the bottom ofthe cylinder is a fine mesh screen that is 75 micronmeter or less. ATeflon disk is placed on top of the film sample to secure it in placeduring the testing. The cylinder containing the sample is placed on topof 4 inch glass fret so that the film sample and screen faced the glassfret. A filter paper is placed between the cylinder and the glass fret.The glass fret, filter and the cylinder is placed in a container thatcontains water so that the height of the water reaches the height of theglass fret. The water continuously being removed and replenished. Theentire set up sits on a Mettler PG3001-S balance. Once the cylindercontaining the sample is placed on the balance, the balance is tared andwater absorption and water absorption rate data is generated using aMettler BalanceLink data acqusition software package. Table 6 lists thecompositions for Examples 43 to 46 and their water adsorption amountsand rates. TABLE 6 Time to reach Time to reach Thermoplastic AMPACET 50%of maximum superabsorbent polymer, Water absorption value, absorptionvalue, Example polymer, parts parts Absorption, g sec sec 43 100   0 155 225 44 90 10 2.2 40 80 45 80 20 2.6 60 120 46 20 80 1.4 45 80

Multilayer Films

[0062] Comparative Examples AX to AZ and Examples 47 to 49 aremultilayer films of thermoplastic superabsorbent polymer blendcompositions produced using a blown film process. The extrudertemperature zones for the thermoplastic superabsorbent polymer blendcomposition (layer 1) range from 250° F. to 300° F. Depending on thepolymer used, the extruder temperature zones for layers 2 and 3 rangefrom 250° F. to 400° F. and die temperatures range from 250° F. to 400°F. The compositions and descriptions of multilayer blown filmComparative Examples AX to AZ and Examples 47 to 49 are shown in Table7.

[0063] Examples 50 to 53 are multilayer blown films prepared asdescribed herein above wherein the level of CABLOC 850-13 is varied in aPRIMACOR blend resin while the composition and ratios of layers 2 and 3are kept constant. The absorption capacity as described hereinabove andthe time to gel block in pure water is determined. The time for thesuperabsorbent polymer to gel the water at its absorption capacity inpure water for the superabsorbent films, referred to as gel block, ismeasured according to the following procedure. A sample of thethermoplastic superabsorbent film composition comprising 0.15 gram ofsuperabsorbent polymer in a vial containing 25.6 grams of distilledwater. The mixture was shaken by hand until it was gel blocked. Theswell initiation time is the time from when the water is added to thefirst observable swelling of the superabsorbent polymer.

[0064] Table 8 lists the compositions and film gauge for multilayerfilms Comparative Example AAA and Examples 50 to 53. Table 9 lists thewater absorption, swell initiation time and time to gel block propertiesfor multilayer films Comparative Examples AAA and Examples 50 to 53 andneat CABLOC 850-13 (Comparative Example AAB). TABLE 7 Exam- Com. Layerratio Gauge ple Ex. Layer 1 composition Layer 2 composition Layer 3composition 1 2 3 mils Product description AX 20 parts CABLOC 1181 100%ATTANE 4201 100% PRIMACOR 3330 20 60 20 4.0 Frequent pinholes in film,80 parts LDPE 681 die face build-up AY 30 parts CABLOC 1181  20% ATTANE4201 100% PRIMACOR 3330 20 60 20 2.0 Frequent pinholes in film, 70 partsELVAX 3180  80% LDPE 681 die face build-up AZ 30 parts CABLOC 80HS 100%ATTANE 4201 100% PRIMACOR 3330 20 60 20 4.5 Some pinholes in film, die70 parts PRIMACOR 3330 face build-up 47 40 parts CABLOC 80HS  30% ATTANE4201 100% PRIMACOR 3330 30 50 20 1.0-2.3 Ran well, no pinholes, no 60parts PRIMACOR 3460  70% LDPE 681 die face build-up. 48 40 parts CABLOC88HS  50% ENGAGE 8100 100% PRIMACOR 3330 30 50 20 2.3 Ran well, nopinholes, no 60 parts ELVALOY 4924  50% LDPE 681 die face build-up. 4940 parts CABLOC 850-13  80% ATTANE 4402 100% PRIMACOR 3330 30 50 20 2.3Ran well, no pinholes, no 60 parts PRIMACOR  20% LDPE 681 die facebuild-up. blend (a)

[0065] TABLE 8 Layer ratio Gauge Example Com. Ex. Layer 1 compositionLayer 2 composition Layer 3 composition 1 2 3 mils AAA 100% PRIMACORblend (a) 80% ATTANE 4201 100% PRIMACOR 3330 30 50 20 4.0 20% LDPE 68150 10 parts CABLOC 850-13 80% ATTANE 4201 100% PRIMACOR 3330 30 50 202.0 90 parts PRIMACOR blend (a) 20% LDPE 681 51 20 parts CABLOC 850-1380% ATTANE 4201 100% PRIMACOR 3330 30 50 20 4.5 80 parts PRIMACOR blend(a) 20% LDPE 681 52 30 parts CABLOC 850-13 80% ATTANE 4201 100% PRIMACOR3330 30 50 20 1.0-2.3 70 parts PRIMACOR blend (a) 20% LDPE 681 53 40parts CABLOC 850-13 80% ATTANE 4201 100% PRIMACOR 3330 30 50 20 2.3 60parts PRIMACOR blend (a) 20% LDPE 681

[0066] TABLE 9 Com. Water Swell Initiation Time to Gel Example Ex.Absorption, g Time, sec Block, sec AAA  0 50  127.25 <15 Did not gelblock 51 203.3 <15 840-900 52 225.9 <10 360-420 53  257.65  <5  90-200AAB 180.0  <5 60-90

Multilayer Films Coated with a Surfactant Solution

[0067] Examples 54 to 57 use a 2.0 mil multilayer blown film. Themultilayer film comprises as layer 1 a thermoplastic superabsorbentpolymer blend comprising 60 weight percent of a 50:50 blend of PRIMACOR3460/PRIMACOR 5980 and 40 weight percent CABLOC T5066 F, as layer 2 aLDPE 4005 and as layer 3 PLEXAR 107 an EVA g-MAH from Equistar. Theextruder temperature zones for the thermoplastic superabsorbent polymerblend composition (layer 1) range from 250° F. to 300° F., the zonetemperatures for layer 2 range from 305° F. to 310° F. and the zonetemperatures for layer 3 range from 350° F. to 370° F. The thicknessratio for layers 1:2:3 is 30:50:20. Layer 1, the thermoplasticsuperabsorbent layer, of the multilayer film is sprayed with asurfactant solution ranging from 0 to 8 percent surfactant. Thesurfactant used for the study is an alcohol ether sulfate. After thefilm is sprayed, it is placed in an air circulating oven to dry at atemperature of 50° C. for 1-2 minutes. Water absorption and rate ofabsorption is measured according to procedures in the aforementionedsection. Table 10 summarizes the water absorption amounts and rates forExamples 54 to 57. TABLE 10 Time to Time to Time to reach reach initial50% of maximum Surfactant Water absorp- absorption absorption solution,Absorption, tion, value, value, Example % g sec sec sec 54 0 1.7 15  60170 55 2 2.0 0 31 112 56 5 1.9 0 29 160 57 8 1.8 0 27 135

Superabsorbent Film and Metal Laminate

[0068] Example 58 is the multilayer film described in Example 53laminated to 6.0 mils Electrically Chrome Coated Steel (ECCS) via a heatlamination process. The adhesive layer of the film (layer 3) is used tobond the film to the steel surface. The superabsorbent film/metallaminate can find usefulness in power cable and communication cableconstruction. The metallic substrate can provide shielding and thethermoplastic superabsorbent polymer layer can be used to bond to itselfor another substrate and can function to stop, block and absorb water incables. Table 11 shows the adhesion properties for Example 57superabsorbent film and metal laminate. TABLE 11 Peel Strength (a), HeatSeal (a) Jacket (b) Bond Example Film Metal Type (lb/in) Strength,(lb/in) Strength, (lb/in) 58 Example 53 ECCS 5.0 13.1 31.8

Armored Cable

[0069] Superabsorbent films were laminated to the ECCS and slit into2.25 inch wide steel tape. The tape is used to make armored cablesExamples 59 to 62. The steel tape is corrugated to 32 corrugations perinch (corrugation can be achieved with or without oil). The corrugatedtape is longitudinal formed through a series of forming dies. A PVCjacketed insulated copper pair cable core having an outside diameter of0.60 inch is placed inside the formed armored tape. A jacketing resin isthen extruded onto the formed armor tape to make a final cable having afinal outside diameter of 0.742 inch. The final gap between the innerjacket and the armor tape is calculated to be around 0.015 inch (0.381mm).

[0070] The performance of cables comprising the thermoplasticsuperabsorbent polymer laminate (Examples 59 to 62, Table 12) iscompared to cables comprising ZETABON CJBS262 armor tape available fromthe Dow Chemical Company (Comparative Example AAC) and additionallycomprising a non-woven superabsorbent tape 3E252 produced by Lantor Inc.(Comparative Example AAD). Non-woven superabsorbent tapes are the wireand cable industry standard for use in dry cable designs. The non-wovensuperabsorbent tape comprises superabsorbent particles sandwichedbetween two non-woven materials. For this evaluation, the non-wovensuperabsorbent tape is helically wrapped around the copper pair cablecore before placing the cable core inside the formed armor tape. In thewire and cable industry, the non-woven superabsorbent tape is typicallylongitudinal formed around the cable core.

[0071] Water blocking performance of the cables is determined by theEIA/TIA-455-82A (“L-test”). The end of the cable core is taped or sealedso that water can not migrate through the wires of the cable core. Thecable length is 1 meter, test duration is 24 hours, the water column is1 meter and time to penetration is measured. TABLE 12 Laminatecomposition Metallic Example Com. Ex. Film Layer 1 Core Film Layer 2Non-woven tape Time to penetration AAC EAA film 6 mil ECCS EAA film NoWithin 1 minute AAD EAA film 6 mil ECCS EAA film Yes (a) 59 EAA film 6mil ECCS Film 1 No No penetration 60 EAA film 6 mil ECCS Film 2 No Nopenetration 61 EAA film 6 mil ECCS Film 3 No No penetration 62 EAA film6 mil ECCS Film 4 No No penetration

Armor Cable with Thermoplastic Superabsorbent Polymer Coated with aSurfactant

[0072] Superabsorbent films were laminated to the ECCS. Thesuperabsorbent layer of the film is either pre- or post-coated with analcohol ether sulfate surfactant solution. The concentration of thesurfactant solution ranges from 2 weight percent to 8 weight percent. Anantifoaming agent, Dow Coming Anti Foam 1520-US, is also used. Theamount of antifoam used is 2500 ppm. The coated laminate is slit into1.375 inch wide steel tape. The tape is used to make armored cablesExamples 63 to 68 (Table 13). The steel tape is corrugated to 32corrugations per inch (corrugation can be achieved with or without oil).The corrugated tape is longitudinal formed through a series of formingdies. An HDPE core tube, available from United States PlasticCorporation, having an outside diameter of 0.375 inch is placed insidethe formed armored tape. A jacketing resin is then extruded onto theformed armor tape to make a final cable. The final gap between the innerjacket and the armor tape is calculated to be around 0.020 inch (0.508mm).

[0073] The performance of cables comprising the thermoplasticsuperabsorbent polymer laminate (Examples 63 to 68) is compared tocables comprising ZETABON CJBS262 armor tape available from the DowChemical Company (Comparative Example AAC).

[0074] Water blocking performance of the cables is determined by theEIA/TIA-455-82A (“L-test”). The end of the cable core is taped or sealedso that water can not migrate through the wires of the cable core. Thecable length is 1 meter, test duration is 24 hours, the water column is1 meter and time to penetration is measured. TABLE 13 Laminatecomposition Example Com. Ex. Film Layer 1 Metallic Core Film Layer 2Surfactant treatment Time to penetration AAC EAA film 6 mil ECCS EAAfilm Within 1 minute 63 EAA film 6 mil ECCS Film 1 Pre- Pass 64 EAA film6 mil ECCS Film 2 Pre- Pass 65 EAA film 6 mil ECCS Film 2 Post- Pass 66EAA film 6 mil ECCS Film 2 Post- Pass 67 EAA film 6 mil ECCS Film 3Post- Pass 68 EAA film 6 mil ECCS Film 3 Post- Pass

Foam Thermoplastic Superabsorbent Polymer

[0075] Examples 69 to 77 are extruded foams of thermoplasticsuperabsorbent polymer blend compositions. About 12 parts per hundred(pph) HCFC 142B physical blowing agent is used. The extruder temperaturezones range from 110° C. to 150° C. and the die temperature range from85° C. to 90° C. The compositions and description of the foam are shownin Table 14. The resulting foams are soft, flexible and non-friable. Thesuperabsorbent particulates are uniformly distributed on the skin andthroughout the cell structure of the foam. TABLE 14 Thermoplasticsuperabsorbent Example polymer type Foam type 69 1 Semi-porous to closedcell foam 70 2 Semi-porous to closed cell foam 71 3 Semi-porous toclosed cell foam 72 4 Semi-porous to closed cell foam 73 5 Semi-porousto closed cell foam 74 6 Semi-porous to closed cell foam 75 7Semi-porous to closed cell foam 76 8 Semi-porous to closed cell foam 779 Semi-porous to closed cell foam

[0076] The absorption capacity in pure water (WAC) of thermoplasticsuperabsorbent foam Examples 78 to 80 (Table 15) extruded by theabovementioned extrusion foam process is shown in Table 16. The WAC ismeasured according to the following procedure: the foam is cut in 0.125inch by 0.625 in by 0.1.25 to 0.25 inch and an amount of the cut foamsample determined to contained 0.1 gram of the superabsorbent polymer(based on the percent superabsorbent polymer in the foam composition)weighing W1 is placed in 0.150 liter of distilled water and is shaken ona shaker for 2 hours. The water is filtered from the foam through a 75micrometer sieve. The weight of the swollen foam (W2) is then measured.The amount of water absorbed, (Wa) is calculate by the followingformula:

Wa=(W2−W1)*10

[0077] TABLE 15 Thermoplastic superabsorbent polymer Example type FoamWater absorption, g 78 2 Yes 87 79 3 Yes 67 80 3 Yes 43

[0078] From these data it can be concluded that the extrudablethermoplastic superabsorbent polymer blends of the present inventioncomprising one or more superabsorbent polymer and one or morethermoplastic resin wherein the thermoplastic resin comprises afunctional group that interacts with the superabsorbent polymer yieldsthe best balance of superabsorbent polymer containment, processability,formability and absorption properties.

[0079] It has been found that the present invention provides improvedthermoplastic superabsorbent polymer blend compositions and processesfor preparing, among other things, monolayer films, multilayer films,nonwoven webs, sheets, foams, profiles, multilayer laminates, fibers,tubes, rods, pipes and the like. It can be seen that the resulting partsor structures according to the present invention are surprisinglyimproved by the use of the described extrudable thermoplasticsuperabsorbent polymer blend compositions and that extruded, shaped orotherwise fabricated articles will ease manufacture, improve performanceand reduce costs of absorbent articles constructed therefrom.

What is claimed is:
 1. An extrudable thermoplastic superabsorbentpolymer blend composition comprising (a) one or more superabsorbentpolymer and (b) one or more thermoplastic resin comprising a functionalgroup which interacts ionically or covalently with (a).
 2. Theextrudable thermoplastic superabsorbent polymer blend composition ofclaim 1 having a melt draw down rate between about 5 and about 100 feetper minute and a melt tension between about 0.1 and about 10 undertemperature and applied load conditions that give a melt flow rate ofbetween about 0.1 and about 300 g/10 min.
 3. The extrudablethermoplastic superabsorbent polymer blend composition of claim 1wherein the superabsorbent polymer is prepared from water-solubleα,β-ethylenically unsaturated monomers.
 4. The extrudable thermoplasticsuperabsorbent polymer of claim 3 wherein the α,β-ethylenicallyunsaturated monomers is a monocarboxylic acid, a vinyl polycarboxylicacid, an acrylamide or mixtures thereof.
 5. The extrudable thermoplasticsuperabsorbent polymer blend composition of claim 1 wherein thesuperabsorbent polymer is a cellulosic-graft copolymer, a starch-graftcopolymer, a starch-g-poly(acrylic acid), a polyacrylamide; a polyvinylalcohol, a poly(acrylic acid), a copolymer of sulfonic acid groupcontaining monomer, or mixtures thereof.
 6. The superabsorbent polymerof claim 5 is crosslinked, partially neutralized, surface treated orcombinations thereof.
 7. The extrudable thermoplastic superabsorbentpolymer blend composition of claim 1 wherein the thermoplastic resin isa polyacrylic acid, ethylene and acrylic acid copolymer, ethylene,t-butylacrylate and acrylic acid terpolymer, ethylene and methacrylicacid copolymer, ionomers of ethylene and methacrylic acid copolymers,ethylene, vinyl acetate and carbon monoxide terpolymer, ethylene andcarbon monoxide copolymer, ethylene, acrylic acid and carbon monoxideterpolymers, ethylene, n-butylacrylate and carbon monoxide terpolymer orblends thereof.
 8. The extrudable thermoplastic superabsorbent polymerblend composition of claim 1 further comprising a surfactant.
 9. Theextrudable thermoplastic superabsorbent polymer blend composition ofclaims 1, 3 or 8 further comprising a polyethylene, a copolymer ofpolyethylene, a polypropylene, a copolymer of polypropylene or apolystyrene.
 10. A method for preparing an extrudable thermoplasticsuperabsorbent polymer blend composition comprising the step ofcombining: (a) one or more superabsorbent polymer and (b) one or morethermoplastic resin comprising a functional group which interactsionically or covalently with (a).
 11. The method of claim 10 furthercomprising the step of combining (c) a surfactant.
 12. A method forproducing an extruded or molded article of an extrudable thermoplasticsuperabsorbent polymer blend composition comprising the steps of: 1)preparing an extrudable thermoplastic superabsorbent polymer compositioncomprising (c) one or more superabsorbent polymer and (b) one or morethermoplastic resin comprising a functional group which interactsionically or covalently with (a) and 2) extruding or molding saidthermoplastic superabsorbent polymer composition into an extruded ormolded article.
 13. The method of claim 12 wherein the superabsorbentpolymer composition further comprising (c) a surfactant.
 14. The methodof claims 12 or 13 wherein the extruded article is a monolayer film, amultilayer film, a nonwoven web, a sheet, a foam, a profile, amultilayer laminate, a fiber, a tube, a rod or a pipe.
 15. The method ofclaims 12 or 13 wherein the extruded article is a monofilament fiber, abicomponent monofilament fiber, a spun bond nonwoven web, a melt blownnonwoven web, or a composite comprising combinations thereof.
 16. Themethod of claims 12 or 13 wherein the extruded article is a nonwoven webcomprising a spun bond nonwoven web comprising one or more bicomponentfiber, a melt blown nonwoven web comprising one or more bicomponentfiber, or a composite structure comprising at least one layer of one ormore spun bond nonwoven web and at least one layer of one or more meltblown nonwoven web wherein one or more layers of the composite comprisebicomponent fibers.
 17. The composition of claims 1 or 8 in the form ofan extruded or molded article.
 18. The extruded or molded article ofclaim 17 is a monolayer film, a multilayer film, a nonwoven web, asheet, a foam, a profile, a multilayer laminate, a fiber, a tube, a rodor a pipe.
 19. The extruded or molded article of claim 17 is amonofilament fiber, a bicomponent monofilament fiber, a spun bondnonwoven web, melt blown nonwoven web, or a composite comprisingcombinations thereof.
 20. The extruded or molded article of claim 17 isa nonwoven web comprising a spun bond nonwoven web comprising one ormore bicomponent fiber, a melt blown nonwoven web comprising one or morebicomponent fiber, or a composite structure comprising at least onelayer of one or more spun bond nonwoven web and at least one layer ofone or more melt blown nonwoven web wherein one or more layers of thecomposite comprise bicomponent fibers.
 21. The monolayer film ormultilayer film of claim 18 laminated to a metal.
 22. A power cablecomprising the metal laminate of claim
 21. 23. A communications cablecomprising the metal laminate of claim
 21. 24. A power cable comprisingthe monolayer film or multilayer film of claim
 18. 25. A communicationscable comprising the monolayer film or multilayer film of claim
 18. 26.A disposable absorbent device comprising an extruded or molded articleof claim
 18. 27. The disposable absorbent device of claim 26 is adiaper, a sanitary napkin, a tampon, an incontinence product, a hospitalgown or a bed pad.
 28. A disposable absorbent device comprising anextruded or molded article of claim
 19. 29. The disposable absorbentdevice of claim 28 is a diaper, a sanitary napkin, a tampon, anincontinence product, a hospital gown or a bed pad.
 30. A disposableabsorbent device comprising an extruded or molded article of claim 20.31. The disposable absorbent device of claim 30 is a diaper, a sanitarynapkin, a tampon, an incontinence product, a hospital gown or a bed pad.